Initial Inspection and Diagnostic Overview

Engine Coolant: System Inspection

WARNING:

- Never remove the radiator cap or reservoir tank cap when the engine is hot. Serious burns could occur from high pressure fluid escaping from the radiator or reservoir.
- Wrap a thick cloth around the cap. Slowly push down and turn it a quarter turn to allow built-up pressure to escape. Carefully remove the cap by pushing down and turning it all the way.

Checking Cooling System Hoses

Check hoses for the following:

- Improper attachment
- Leaks
- Cracks
- Damage
- Loose connections
- Chafing
- Deterioration

Checking Reservoir Level

- Check if the engine coolant reservoir tank level is within MIN to MAX when the engine is cool.






- Adjust engine coolant level as necessary.

Checking Cooling System for Leaks

WARNING:

Never remove the radiator cap or reservoir cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator or reservoir.

- To check for leakage, apply pressure to the cooling system at the reservoir filler neck using suitable tool and Tool.















CAUTION:
Higher pressure than specified may cause radiator damage.

NOTE:
In case that engine coolant decreases, replenish cooling system with engine coolant.

- If any concerns are found, repair or replace damaged parts.

Checking Reservoir Cap

1) Inspect the reservoir cap.
- Replace the cap if the metal plunger cannot be seen around the edge of the black rubber gasket.
- Replace the cap if deposits of waxy residue or other foreign material are on the black rubber gasket or the metal retainer.

NOTE:
Thoroughly wipe out the reservoir filler neck to remove any waxy residue or foreign material.

2) Pull the negative-pressure valve to open it and check that it closes completely when released.





- Check that there is no dirt or damage on the valve seat of the reservoir cap negative-pressure valve.
- Check that there are no abnormalities in the opening and closing conditions of the negative-pressure valve.
3) Check reservoir cap relief pressure using suitable tool and Tool.















NOTE:
- Apply engine coolant to the cap seal surface.
- Replace the reservoir cap if there is any damage in the negative-pressure valve, or if the open-valve pressure is outside of the limit.

Checking Radiator Cap

Inspect the radiator cap.

NOTE:

Thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material.

- Replace the cap if deposits of waxy residue or other foreign material are on the black rubber gasket or the metal retainer.

Checking Radiator

Check radiator for mud or clogging. If necessary, clean radiator as follows.

CAUTION:

- Be careful not to bend or damage the radiator fins.
- When radiator is cleaned without removal, remove all surrounding parts such as cooling fan shroud and horns. Then tape the harness and electrical connectors to prevent water from entering.

1) Spray water to the back side of the radiator core using a side to side motion from the top down.
2) Stop spraying when debris no longer flows from radiator core.
3) Blow air into the back side of radiator core using a side to side motion from the top down.
- Use compressed air lower than 490 kPa (5 kg/cm2, 71 psi) and keep distance more than 30 cm (11.8 in).
4) Continue to blow air until no water sprays out.
5) Check for coolant leaks. Repair as necessary.